MES Implementation for Defense Production
How Inteched delivered a fully integrated Manufacturing Execution System for a defense production facility, enabling real-time production visibility, traceability, and compliance across complex assembly lines.
Industry
Defense Manufacturing
Duration
10 Months
Services
MES Integration, Systems Architecture, Industrial IoT, Compliance Engineering, DevOps
Context
The client is a mid-to-large defense production company operating multiple assembly lines for complex electromechanical systems. Prior to this engagement, their production operations relied on a combination of legacy paper-based processes and siloed digital tools, with no unified visibility across the shop floor. Each assembly line operated in relative isolation, with production data captured manually or stored in disconnected systems that could not communicate with one another. This fragmentation made it impossible for production managers to gain a real-time picture of work-in-progress, resource utilisation, or quality status at any given moment.
Operating within the defense sector, the client faced stringent regulatory and traceability obligations under frameworks including NATO AQAP-2110 and applicable MIL-SPEC standards. These requirements demanded a fully auditable, traceable record of every production event, component, and quality decision — a standard their existing processes could not reliably meet. Inteched was engaged to design and deploy a modern Manufacturing Execution System (MES) platform that would integrate seamlessly with their existing ERP (SAP) and SCADA infrastructure, replacing fragmented workflows with a single, authoritative source of production truth.
The Problem
No Real-Time Production Visibility
Production managers had no live view of work-in-progress across assembly lines, leading to delays, bottlenecks, and reactive decision-making.
Fragmented Data & Siloed Systems
ERP, SCADA, and quality management systems operated independently with no data exchange, causing manual reconciliation and high error rates.
Traceability & Compliance Gaps
Meeting AQAP-2110 and MIL-SPEC traceability requirements was manual and error-prone, creating audit risk and potential contract non-compliance.
Unplanned Downtime & OEE Loss
Without predictive maintenance data or real-time equipment telemetry, unplanned stoppages were frequent and costly.
Our Approach
1. Discovery & Process Mapping
Conducted a 6-week discovery phase across all production lines, mapping existing workflows, data flows, and integration points with ERP (SAP) and SCADA systems. Identified 14 critical integration gaps.
Phase 12. MES Architecture Design
Designed a modular MES architecture based on ISA-95 standards, with dedicated modules for production scheduling, work order management, quality control, and equipment monitoring. Chose an on-premise deployment with a secure DMZ for ERP connectivity.
Phase 23. Integration & Development
Built bidirectional integrations between the MES, SAP ERP, and SCADA layer using OPC-UA and REST APIs. Developed custom traceability workflows aligned with AQAP-2110 requirements, including electronic batch records and digital sign-off.
Phase 34. Pilot Deployment & Validation
Deployed the MES on a single pilot assembly line, running in parallel with legacy processes for 8 weeks. Conducted IQ/OQ/PQ validation and resolved 23 integration edge cases before full rollout.
Phase 45. Full Rollout & Training
Rolled out across all production lines with a phased cutover plan. Delivered role-based training to 120+ operators, supervisors, and quality engineers. Established a hypercare support period of 4 weeks post-go-live.
Phase 5The Outcome
Overall Equipment Effectiveness gain within 3 months of go-live
Full digital traceability across all production orders and components
Reduction in manual data entry and paper-based reporting
Reduction in time required to prepare for compliance audits
